Timing Chain: Service and Repair

REMOVAL AND INSTALLATION













- MB991454: Engine Hanger Balancer
- MB991895: Engine Hanger
- MB991928: Engine Hanger
- MB991448: Bush Remover And Installer Base

REMOVAL SERVICE POINTS

[[A]] POWER STEERING OIL PUMP ASSEMBLY REMOVAL

1. Remove the power steering oil pump assembly with hose on it.

2. Tie the removed power steering oil pump with a string at a position where it will not interfere with the removal and installation of timing chain.

[[B]] ENGINE AND TRANSAXLE ASSEMBLY HOLDING

Install a special tool for holding the engine and transaxle assembly.













1. [Engine hanger MB991928 is used]
(1) Assemble the engine hanger (special tool MB991928). Set the following parts on the base hanger.

- Slide bracket (HI)
- Foot x 4 (standard) (MB991932)
- Joint x 2 (140) (MB991931)
(2) Set the foot of the special tool as shown in the figure.
NOTE:
Slide the slide bracket (HI) to adjust the engine hanger balance.

(3) Mount special tool MB991454 to the power steering oil pump bracket and the engine hanger, and set it to special tool MB991928 to support the engine and transaxle assembly.













2. [Engine hanger MB991895 is used]
(1) Set the foot of special tool MB991895 as shown in the figure.
NOTE:
Slide the foot to adjust the engine hanger balance.

(2) Mount special tool MB991454 to the power steering oil pump bracket and the engine hanger, and set it to special tool MB991895 to support the engine and transaxle assembly.

[[C]] CRANKSHAFT PULLEY REMOVAL

When removing the crankshaft pulley, slightly loosen the water pump pulley mounting bolts before removal of the drive belt.

[[D]] AUTO-TENSIONER REMOVAL





Loosen the mounting bolt of generator assembly lower part, and remove the mounting bolt of generator assembly upper part. Slide the generator assembly, and remove the auto-tensioner.

[[E]] TIMING CHAIN CASE ASSEMBLY REMOVAL





1.
CAUTION:
If the adhesive strength of sealant on the timing chain case assembly is so strong that the boss may be damaged by peeling off, do not peel it off forcibly.

After removing the timing chain case assembly mounting bolts, slightly pry the boss of the timing chain case assembly shown in the figure using a flat-tipped screwdriver, and remove the timing chain case assembly from the cylinder head and cylinder block.





2. If the sealant cannot be peeled off easily, insert a wooden hammer shank into the timing chain case assembly inside as shown in the figure, pry slightly, and remove the timing chain case assembly from the cylinder head and cylinder block.

[[F]] TIMING CHAIN TENSIONER REMOVAL

1. Temporarily install the crankshaft pulley to the crankshaft.





2.
CAUTION:
Turn the crankshaft clockwise.

Turn the crankshaft clockwise to align the sprocket timing marks as shown in the figure and set the cylinder No. 1 to the top dead center of compression stroke.
NOTE:
At this time, it is not necessary that the link plate (blue) of the timing chain always aligns with each sprocket timing mark.

3. Remove the crankshaft pulley installed temporarily.





4. Using a flat-tipped precision screwdriver, release the ratchet of timing chain tensioner.
5. Compress the plunger of timing chain tensioner and insert hard wire (such as piano wire) or the L-shaped hexagon wrench (1.5 mm[0.05 inch]) to fix the plunger of the timing chain tensioner.
6. Remove the timing chain tensioner.

INSTALLATION SERVICE POINTS

]]A[[ TIMING CHAIN INSTALLATION





1. Set the timing marks of the camshaft sprockets and the crankshaft sprocket as shown in the figure.





2. Align each sprocket timing chain mating mark with the link plate (blue) of timing chain to avoid slack of the timing chain tension side, and install the timing chain to the sprockets.

]]B[[ TIMING CHAIN TENSIONER INSTALLATION





1. Check that the sprocket timing chain mating marks align with the link plates (blue) of the timing chain, and install the timing chain tensioner to the cylinder block.





2. Remove the hard wire or L-shaped hexagon wrench fixing the plunger of the timing chain tensioner to apply tension to the timing chain.

]]C[[ CRANKSHAFT FRONT OIL SEAL INSTALLATION

1. Apply a small amount of engine oil to the entire inner diameter of the oil seal lip.





2.
CAUTION:
When installing the crankshaft oil seal, be careful to avoid damage to the crankshaft front oil seal.

Using special tool MB991448, press in the crankshaft front oil seal up to the chamfered surface of timing chain case.

]]D[[ TIMING CHAIN CASE ASSEMBLY INSTALLATION

1.
CAUTION:

- Be sure to remove the sealant remaining in the mounting hole, O-ring groove, and gap between parts.
- After degreasing with degreasing agent, check that there is no oil on the surface where the sealant is applied.
- After degreasing with degreasing agent, never touch the degreased area with fingers.

Remove sealant from the timing chain case assembly and the timing chain case assembly mounting surface of the cylinder block and the cylinder head, and degrease the surface where the sealant is applied.

2. Remove all the sealant adhering to the gasket between the cylinder head and cylinder block (three-surface aligned part.) Then, degrease the surfaces.

3. As for the three-surface aligned part that is indicated in Step 2 above, the engine oil oozes from the cylinder head gasket. Thus, quickly apply the sealant to it after degreasing.





4. To the timing chain case assembly mating surface, apply the sealant with a width of 2.5 ± 0.5 mm (0.1 ± 0.02 inch) and without a gap. However, with the "A" shown in the figure, apply the sealant with overlapping the diameter of 4.5 ± 0.5 mm (0.18 ± 0.02 inch) or 2.5 ± 0.5 mm (0.1 ± 0.02 inch) as shown in the figure.
Specified sealant: Three bond 1217G or equivalent
5.
CAUTION:

- If the sealant contacts any other part during installation of the timing chain case assembly, apply sealant again before installing the timing chain case assembly.
- After the installation, until a sufficient period of time (one hour or more) elapses, do not apply the oil or water to the sealant application area or start the engine.

Install the timing chain case assembly to the cylinder block and cylinder head so that the sealant does not contact other parts.
NOTE:
Install the timing chain case assembly immediately after applying sealant.





6. To the installation positions shown in the figure, tighten the timing chain case assembly mounting bolts to the specified torque shown below.






]]E[[ WATER PUMP PULLEY INSTALLATION

Temporarily tighten the water pump pulley mounting bolts. Then, tighten them to the specified torque after the installation of drive belt.

Tightening torque: 9.0± 1.0Nm (80± 9 in-lb)